Actuators with condition tracking

ABSTRACT

An actuator may include a drive motor, an actuatable output, and a sensor for sensing a first sensed parameter in or around the actuator. The first sensed parameter may have a first sensed parameter value that can change with time. The actuator may also include electronics that may identify a first identified value representative of the first sensed parameter value and increment a first counter value when the first identified value falls within a first range of values, and increment a second counter value when the first identified value falls within a second range of values.

The is a continuation of co-pending U.S. patent application Ser. No.15/719,517, filed Sep. 28, 2017, which is incorporated herein byreference.

TECHNICAL FIELD

The disclosure relates generally to building automation systems, andmore particularly to actuators for building automation systems.

BACKGROUND

Building automation systems can include building control systems such asa Heating, Ventilation and/or Air Conditioning (HVAC) system, asecurity/access control system, a lighting system, a fire system and/orother building control system of a building. Many such building controlsystems include one or more mechanical actuators for actuating abuilding component such as a valve, a damper, a door lock and/or otherbuilding component. Such actuators are often used until failure, and insome cases, such failure may go unnoticed for an extended period oftime. During this time, the corresponding building control system mayperform in a sub-optimal manner. For example, in an HVAC system, if adamper actuator that controls the flow of conditioned air to a zone of abuilding fails, the zone may become over-conditioned (e.g. the damper isstuck open) or under conditioned (e.g. the damper is stuck closed). Thismay lead to wasted energy and/or a reduction in occupant discomfortuntil the damper actuator failure is discovered and is replaced.

In some cases, a calendar based maintenance program may be establishedfor each building component of a building automation system. A calendarbased maintenance program typically dictates when each of the buildingcomponent should be replaced based on a worst case scenario so thatstatistically the building components will be replaced before they fail.While such calendar based maintenance programs may be useful inmaintaining the building control system, some of the building componentswill be replaced pre-maturely while others may fail before the indicatedreplacement date. In example, some mechanical actuators may not beactuated very often, and/or operated in a way or under operatingconditions that allow the mechanical actuators to continue to operatefor an extended period of time beyond that which is assumed by thecalendar based maintenance program. Likewise, some mechanical actuatorsmay be actuated very often, and/or operated in a way or under operatingconditions that causes the mechanical actuators to fail before the dateassumed by the calendar based maintenance program. The actual failuredate of an actuator may depend on a variant of factors that are notconsidered by a calendar based maintenance program including forexample, the particular building component in the building controlsystem that is being controlled, the placement and/or actual operationof the mechanical actuator, the environmental conditions surrounding themechanical actuator, as well as other factors.

What would be desirable is an actuator that tracks various localparameters over time, and then use those local parameters to determinean expected failure date for the particular actuator. The actuator maythen be replaced before the expected date of failure.

SUMMARY

The disclosure describes systems, methods, and executable programs thatallow an installer or other user to have more insight into the health orstatus of an actuator and allow a user to take the proper course ofaction so that a building control device of a building automation systemmay be replaced in a more optimal manner. This may be accomplished byhaving an actuator track various local parameters over time. These localparameters may then be used to determine an expected failure date forthe particular actuator. The actuator may then be replaced before theexpected date of failure.

In an example of the disclosure, an actuator for actuating a buildingcontrol device of a building automation system may include a drivemotor, an actuatable output coupled to and driven by the drive motor,and a first sensor for sensing a first sensed parameter in or around theactuator. The first sensed parameter may have a first sensed parametervalue that can change with time. Electronics may be operatively coupledto the first sensor and may be configured to repeatedly identify a firstidentified value representative of the first sensed parameter value andfor each first identified value, the electronics may increment a firstcounter value when the first identified value falls within a first rangeof values, and may increment a second counter value when the firstidentified value falls within a second range of values, wherein thefirst range of values is different from the second range of values. Eachof these counter values may then represent the amount of time that thefirst sensed parameter value was in the corresponding range of values.

In one concrete example, the first sensed parameter value may be atemperature in or around the actuator. A range of temperature values(e.g. −50 F to 125 F) may be divided into a plurality of ranges ofvalues (e.g. each range of values being 5 F, resulting in 35 ranges ofvalues). A counter may be assigned to each range of values (e.g. 35counters). Then, during operation, a measure of temperature may bedetermined every minute, and the counter corresponding to the range ofvalues that corresponds to the measure of temperature may beincremented. This may be repeated over time. The resulting countervalues may then represent a histogram of the temperature history in oraround the actuator. This data may be used to help predict when theactuator will fail.

It is contemplated that this may be carried out for multiple sensedparameter values, and the resulting data may be used to help betterpredict when the actuator will fail. According to various embodiments,the sensed parameter values may be indicative of the status of thesurroundings or environment of the actuator and/or the state oroperating status of the actuator itself. For example, in some cases, thesensed parameter values may include the operational load current of theactuator, the internal temperature of the actuator, the temperaturesurrounding the actuator, the humidity levels surrounding the actuator,the atmospheric pressure surrounding the actuator, the differentialpressure associated with the operation of the actuator (e.g. a damperactuator), the speed and direction of the air surrounding the actuator,the quality of the air surrounding the actuator, the number of actuatoropenings, the number of actuator closings, the number of actuatorstalls, the speed of the actuator at each stall, etc. These are justsome examples.

Alternatively or additionally to the foregoing, the electronics may beconfigured to identify a first identified value representative of thefirst sensed parameter value at a first predetermined rate.

Alternatively or additionally to any of the embodiments above, theelectronics may be configured to sample a first sensor for the firstsensed parameter value at a second predetermined rate, wherein thesecond predetermined rate is faster than the first predetermined rate.

Alternatively or additionally to any of the embodiments above, theelectronics may be configured to identify a first identified value byaveraging the first sensed parameter values that have been sampled sincethe last first identified value was identified.

Alternatively or additionally to any of the embodiments above, theelectronics may be configured to identify a first identified value byselecting one of the first sensed parameter values that have beensampled since the last first identified value was identified.

Alternatively or additionally to any of the embodiments above, the firstidentified value representative of the first sensed parameter value maybe the first sensed parameter value.

Alternatively or additionally to any of the embodiments above, furthercomprising a second sensor for sensing a second sensed parameter in oraround the actuator, wherein the second sensed parameter has a secondsensed parameter value that can change with time, and the electronicsmay be further configured to repeatedly identify a second identifiedvalue representative of the second sensed parameter value, and for eachfirst identified value, may increment a third counter value when thesecond identified value falls within a third range of values, and mayincrement a fourth counter value when the second identified value fallswithin a fourth range of values, wherein the third range of values maybe different from the fourth range of values.

Alternatively or additionally to any of the embodiments above, the firstsensor may be a temperature sensor, and the second sensor is a loadcurrent sensor.

Alternatively or additionally to any of the embodiments above, furthercomprising a transmitter for transmitting the first counter value andthe second counter value to a remote device.

Alternatively or additionally to any of the embodiments above, theelectronics may be further configured to calculate a probability offailure of the actuator based at least in part on the first countervalue and the second counter value.

Alternatively or additionally to any of the embodiments above, furthercomprising a receiver for receiving a failure model from a remotedevice, wherein the electronics may be configured to use the failuremodel to calculate the probability of failure of the actuator.

Alternatively or additionally to any of the embodiments above, theelectronics may be further configured to increment a stall counter formaintaining a count of a number of stalls experienced by the actuator.

Alternatively or additionally to any of the embodiments above, theelectronics may be further configured to increment a cycle counter formaintaining a count of a number of open/close cycles and/or number ofposition changes of the actuatable output experienced by the actuator.

In another example of the disclosure, an actuator for actuating abuilding control device of a building automation system may comprise adrive motor, an actuatable output coupled to and driven by the drivemotor, a first sensor for sensing a first sensed parameter in or aroundthe actuator, wherein the first sensed parameter may have a first sensedparameter value that can change with time, a second sensor for sensing asecond sensed parameter in or around the actuator, wherein the secondsensed parameter may have a second sensed parameter value that canchange with time, and electronics operatively coupled to the firstsensor and the second sensor. The electronics may be configured torepeatedly identify a first identified value representative of the firstsensed parameter value, repeatedly identify a second identified valuerepresentative of the second sensed parameter value, increment a firstcounter value when the first identified value falls within a first rangeof values and the second identified value falls within a second range ofvalues, increment a second counter value when the first identified valuefalls within a third range of values and the second identified valuefalls within the second range of values, increment a third counter valuewhen the first identified value falls within the first range of valuesand the second identified value falls within a fourth range of values,and increment a fourth counter value when the first identified valuefalls within the second range of values and the second identified valuefalls within the fourth range of values.

Alternatively or additionally to any of the embodiments above, theelectronics may be configured to identify a first identified valuerepresentative of the first sensed parameter value, identify a secondidentified value representative of the second sensed parameter value,and increment the first, second, third and fourth counter values, asappropriate, at a predetermined rate.

Alternatively or additionally to any of the embodiments above, the firstsensor may be a temperature sensor, and the second sensor may be a loadcurrent sensor.

Alternatively or additionally to any of the embodiments above, furthercomprising a transmitter for transmitting the first counter value, thesecond counter value, the third counter value and the fourth countervalue to a remote device.

Alternatively or additionally to any of the embodiments above, theelectronics may be further configured to calculate a probability offailure of the actuator based at least in part on the first countervalue, the second counter value, the third counter value and the fourthcounter value.

Alternatively or additionally to any of the embodiments above, furthercomprising a receiver for receiving a failure model from a remotedevice, wherein the electronics may be configured to use the failuremodel to calculate the probability of failure of the actuator.

In another example of the disclosure, a method for estimating aprobability of failure of an actuator may comprise sensing a firstsensed parameter in or around the actuator, wherein the first sensedparameter may have a first sensed parameter value that can change withtime. Repeatedly identifying a first identified value representative ofthe first sensed parameter value. For each first identified value,incrementing a first counter value when the first identified value fallswithin a first range of values, and incrementing a second counter valuewhen the first identified value falls within a second range of values,wherein the first range of values may be different from the second rangeof values. A probability of failure of the actuator is then calculatedbased at least in part on the first counter value and the second countervalue.

The above summary of some illustrative embodiments is not intended todescribe each disclosed embodiment or every implementation of thepresent disclosure. The Figures and Description which follow moreparticularly exemplify these and other illustrative embodiments.

BRIEF DESCRIPTION OF THE FIGURES

The disclosure may be more completely understood in consideration of thefollowing description in connection with the accompanying drawings, inwhich:

FIG. 1 is a schematic block diagram of an illustrative actuator;

FIGS. 2A-2E show an exemplary counter table over time;

FIG. 2F is a graphical representation of the counter table of FIG. 2E;

FIG. 3A-3E show another exemplary counter table over time;

FIG. 3F is a graphical representation of the counter table of FIG. 3E;

FIG. 4 shows an exemplary two-dimensional counter table;

FIG. 5A is another exemplary counter table;

FIG. 5B is a graphical representation of the counter table of FIG. 5A;

FIG. 6 is a schematic block diagram of an illustrative building controlsystem;

FIG. 7 is a schematic block diagram of another illustrative buildingcontrol system; and

FIG. 8 is a flow diagram of an illustrative method.

While the disclosure is amenable to various modifications andalternative forms, specifics thereof have been shown by way of examplein the drawings and will be described in detail. It should beunderstood, however, that the intention is not to limit the disclosureto the particular embodiments described. On the contrary, the intentionis to cover all modifications, equivalents, and alternatives fallingwithin the spirit and scope of the disclosure.

DESCRIPTION

For the following defined terms, these definitions shall be applied,unless a different definition is given in the claims or elsewhere inthis specification.

All numeric values are herein assumed to be modified by the term“about,” whether or not explicitly indicated. The term “about” generallyrefers to a range of numbers that one of skill in the art would considerequivalent to the recited value (i.e., having the same function orresult). In many instances, the terms “about” may include numbers thatare rounded to the nearest significant figure.

For the following defined terms, these definitions shall be applied,unless a different definition is given in the claims or elsewhere inthis specification.

All numeric values are herein assumed to be modified by the term“about,” whether or not explicitly indicated. The term “about” generallyrefers to a range of numbers that one of skill in the art would considerequivalent to the recited value (i.e., having the same function orresult). In many instances, the terms “about” may include numbers thatare rounded to the nearest significant figure.

The recitation of numerical ranges by endpoints includes all numberswithin that range (e.g. 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and5).

As used in this specification and the appended claims, the singularforms “a”, “an”, and “the” include plural referents unless the contentclearly dictates otherwise. As used in this specification and theappended claims, the term “or” is generally employed in its senseincluding “and/or” unless the content clearly dictates otherwise.

It is noted that references in the specification to “an embodiment”,“some embodiments”, “other embodiments”, etc., indicate that theembodiment described may include one or more particular features,structures, and/or characteristics. However, such recitations do notnecessarily mean that all embodiments include the particular features,structures, and/or characteristics. Additionally, when particularfeatures, structures, and/or characteristics are described in connectionwith one embodiment, it should be understood that such features,structures, and/or characteristics may also be used connection withother embodiments whether or not explicitly described unless clearlystated to the contrary.

The following description should be read with reference to the drawingsin which similar structures in different drawings are numbered the same.The drawings, which are not necessarily to scale, depict illustrativeembodiments and are not intended to limit the scope of the disclosure.

Certain embodiments of the present disclosure may be found in a system,a method, and/or a non-transitory computer-readable storage medium withan executable program stored thereon for implementing parametercollection operations to obtain information regarding actuators used inbuilding control devices. In various embodiments, controller(s) may beconfigured to direct the operation of actuators included with and/or inbuilding control devices of a building automation system located in oraround a building. By collecting the various parameters over time,insight into the performance of specific actuators and descriptions ofthe status of the actuators may be obtained. In some cases, this datamay be used to determine an expected failure date for each actuator, andas such the actuators may be replaced before the expected date offailure.

FIG. 1 depicts an illustrative actuator 100 that may be used inconjunction with building control devices in a building automationsystem. While a building control actuator is used as an example, it iscontemplated that the present disclosure may be applied to any suitableactuator, including automotive actuators, process control actuators, andother actuators. As shown, the actuator 100 includes electronics 102,housing 132, sensors 114, 116, a drive motor 118, and an actuatableoutput 120. In some cases, the electronics 102 may respond to an outputsignal from a remote controller (not shown in FIG. 1) and use the drivemotor 118 to provide the mechanical action to move the actuatable output120 that then operates a mechanism (e.g., a valve or damper) of abuilding control device. In some cases, the electronics 102 may includea processing module 104, an electrical sensing module 106, a mechanicalsensing module 108, a communications module 110, and memory 112. It iscontemplated that the electronics 102 may include more or less modulesthan those shown in FIG. 1, depending on the application.

The electrical sensing module 106 may be configured to sense one or moreparameters in or around the actuator 100. In some examples, theparameters may include electrical activity associated with the actuator100 and the electrical sensing module 106 may include one or moresensors to detect the electrical activity, such as at the terminals ofthe actuator 100 and/or elsewhere in the electronics 102. For example,the electrical sensing module 106 may be connected to the sensors 114,116 and the electrical sensing module 106 may be configured to sense theparameters (e.g. load current, load voltage, signal degradation, etc.)within or surrounding the actuator 100 via the sensors 114, 116.

In some examples, the mechanical sensing module 108, may be configuredto sense one or more parameters in or around the actuator 100. Forexample, in certain embodiments, the mechanical sensing module 108 mayinclude one or more sensors, such as a temperature sensor, anaccelerometer, a pressure sensor, a humidity sensor, an air flow orvelocity sensor, a chemical sensor (e.g. air quality sensor), and/or anyother suitable sensor that is configured to detect one or moremechanical/chemical parameters in or around the actuator 100. Both theelectrical sensing module 106 and the mechanical sensing module 108 maybe connected to the processing module 104 and provide signalsrepresentative of the sensed parameter(s). Although described withrespect to FIG. 1 as separate sensing modules, in some cases, theelectrical sensing module 106 and the mechanical sensing module 108 maybe combined into a single sensing module, as desired.

According to various embodiments, the parameters may be indicative ofthe status of the surroundings or environment of the actuator 100 and/orthe state or operating status of the actuator 100 itself. For example,in some cases, the parameters may include the operational load currentof the actuator 100, the internal temperature of the actuator 100, thetemperature surrounding the actuator 100, the humidity levelssurrounding the actuator 100, the atmospheric pressure surrounding theactuator 100, the differential pressure associated with the operation ofthe actuator 100 (e.g. a damper actuator), the speed and/or direction ofthe air surrounding the actuator 100, the quality of the air surroundingthe actuator 100, etc. In some cases, the status of the surroundings ofthe actuator 100 and/or the state of the actuator 100 may provideinformation relevant to helping to predict the operational lifetime ofthe actuator 100. In such cases, the parameters may be used to calculatea probability of failure of the actuator 100 over time.

In some cases, some of the illustrative sensors 114, 116 may be securedrelative to the inside and/or outside of the housing 132 of the actuator100 and may be exposed to the atmosphere inside and/or outside of theactuator 100. In some examples, the sensors 114, 116 may be inelectrical communication with one or more of the modules 104, 106, 108,110 and memory 112. The sensors 114, 116 may be supported by the housing132. In some examples, the sensors 114, 116 may be connected to thehousing 132 through short connecting wires such that the sensors 114,116 are not directly secured relative to the housing 132 but ratherlocated remotely from the housing. In some cases, the remote sensors114, 116 may increase the number of electrodes by which the actuator 100may sense parameters, and/or communicate with a remote device. In someexamples, the sensors 114, 116 may be integrated with the electronics102 (e.g., with the electrical sensing module 106 and the mechanicalsensing module 108). In certain embodiments, where the sensors 114, 116include temperature sensors, the sensors 114, 116 may include platinumresistance thermometers, thermistors, nickel resistance thermometers,etc. In certain embodiments, where the sensors 114, 116 include humiditysensors, the sensors 114, 116 may include capacitive sensors, dew pointsensors, etc. In certain embodiments, where the sensors 114, 116 includepressure sensors, the sensors 114, 116 may include capacitive sensors,inductive sensors, strain gauge sensors, potentiometers, etc. In certainembodiments, where the sensors 114, 116 include velocity or flowsensors, the sensors 114, 116 may include pitot tubes, hot wireanemometers, orifice plates, turbine flow meters, etc. In certainembodiments, where the sensors 114, 116 include air quality sensors(e.g., gas sensors), the sensors 114, 116 may include CO₂ sensors,multi-gas sensors, specified pollutant sensors, obscuration sensors,etc. In some instances, the sensors 114, 116 connected to the actuator100 may have an insulative portion that electrically isolates thesensors 114, 116 from adjacent sensors, the housing 132, and/or otherparts of the actuator 100.

The processing module 104 may include electronics that are configured tocontrol the operation of the actuator 100. The processing module 104 mayfurther be configured to obtain electrical signals from the electricalsensing module 106 and/or the mechanical sensing module 108 indicativeof parameter value(s). In some embodiments, the processing module mayobtain the parameter value(s) at a set rate or rate(s) (e.g.predetermined sample rate) and measure the rates using a clock 126. Theprocessing module 104 may use an analyzer block 124 to analyze ormeasure the signals to identify the parameter value(s). The processingmodule 104 may then use a counter block 122 to increment a countervalue(s) based on the identified the parameter value(s). In some cases,the processing module 104 may be configured to instruct thecommunication module 110 to use a transmitter 128 to transmit thecounter value(s) to remote devices (e.g., a controller, a server, over anetwork, etc.).

In some cases, the processing module 104 may be configured to use theanalyzer block 124 to calculate a probability of failure of the actuator100 over time and/or other actuators using the counter value(s). In somecases, the processing module 104 may instruct the communication module110 to use receiver 130 to receive an actuator failure model 138 from aremote device (e.g., a controller, a server, over a network, etc.) andapply, compare, and/or measure the counter value(s) against the failuremodel 138 and obtain a probability of failure of the actuator 100 overtime.

In some cases, the processing module 104 may receive electrical signalsfrom the electrical sensing module 106 and/or the mechanical sensingmodule 108 indicative of the state of the actuatable output 120 and/orposition value(s) of the actuatable output 120. The processing module104 may use the analyzer block 124 to analyze the state of theactuatable output 120 to determine whether the actuatable output 120 hasstalled and/or analyze the position value(s) to determine whether theactuatable output 120 is in an open/closed position or whether apositional change of the actuatable output 120 has occurred. Theprocessing module 104 may use the counter block 122 to increment one ormore counter value(s) based on the analysis of the state of theactuatable output 120 and/or position value(s).

In some examples, the processing module 104 may include a pre-programmedchip, such as a very-large-scale integration (VLSI) chip and/or anapplication specific integrated circuit (ASIC). In such embodiments, thechip may be pre-programmed with control logic in order to control theoperation of the actuator 100. In some cases, the pre-programmed chipmay implement a state machine that performs the desired functions. Byusing a pre-programmed chip, the processing module 104 may use lesspower than other programmable circuits (e.g. general purposeprogrammable microprocessors) while still being able to maintain basicfunctionality. In other examples, the processing module 104 may includea programmable microprocessor. Such a programmable microprocessor mayallow a user to modify the control logic of the actuator 100 even whenalready installed, thereby allowing for greater flexibility of theactuator 100 than when using a pre-programmed ASIC.

The memory 112 of the actuator 100 may include volatile and/ornon-volatile memory. The counter values are preferable stored innon-volatile memory so that the values are not lost if power is lost tothe actuator. In some cases, program/utility 134 may be stored in thememory 112 and may include a set of application program modules (e.g.software), such as a parameter counter module 136. In some cases, theprogram/utility 134 may include additional program modules as well as anoperating system, one or more other application program modules, and/orprogram data. According to various embodiments, the application programmodules (e.g., the parameter counter module 136) may include an actuatorfailure model 138, for example. In certain embodiments, the parametercounter module 136, including the actuator failure model 138, may beassembler instructions, instruction-set-architecture (ISA) instructions,machine instructions, machine dependent instructions, microcode,firmware instructions, state-setting data, or either source code orobject code written in any combination of one or more programminglanguages, including an object oriented programming language such asSmalltalk, C++ or the like, and conventional procedural programminglanguages, such as the “C” programming language or similar programminglanguages.

The parameter counter module 136 may execute on the actuator 100. Insome cases, the parameter counter module 136 may execute on a remotedevice (e.g., a controller or server). In some cases, part of theparameter counter module 136 may be executed on the actuator 100 andpart of the parameter counter module 136 may be executed on a remotedevice. In the latter scenario, the remote device may be connected tothe communication module 110 of the actuator 100 through any type ofnetwork, including a local area network (LAN) or a wide area network(WAN), or the connection may be made to an external computer (forexample, through the Internet using an Internet Service Provider). Incertain embodiments, the communication module 110 may be configured tocommunicate with the remote device to receive and provide diagnosticinformation (e.g., counter value(s), the failure model 138, aprobability of failure of the actuator 100) about the actuator 100and/or other information regarding the actuator 100. For example, insome cases, the actuator 100 may receive a failure model 138 in the formof signals, data, commands or instructions and/or messages from a serverof the building automation system through the receiver 130 of thecommunication module 110. The processing module 104 may then measurecounter value(s) against the failure model 138 to determine aprobability of failure of the actuator 100. The processing module 104may then instruct the communication module 110 to use the transmitter128 to send the probability of failure of the actuator 100 in the formof signals, data, commands or instructions and/or messages back to theserver. The communication module 110 may be configured to use one ormore methods for communicating with external devices. For example, thecommunication module 110 may communicate via wired communication,radiofrequency (RF) signals, optical signals, acoustic signals, and/orany other signals suitable for communication.

FIGS. 2A-2E show an exemplary counter table over time. As stated herein,an actuator (e.g., actuator 100, from FIG. 1) may use sensors (e.g.,electrical sensors, temperature sensors, accelerometers, pressuresensors, humidity sensors, air flow or velocity sensors, chemicalsensors, etc.) to continuously sense signals (which can includediscretely sampled signals at a sample interval) to obtain parameters inor around the actuator. These parameters may be indicative of the statusof the surroundings or environment of the actuator and/or the operatingstatus of the actuator. Since the actuators surroundings and theactuators operating status may change over time, the parameters may alsochange over time. As such, in some cases, the actuator may repeatedlyidentify parameter values from the parameters at a specific rate orrates. The actuator may analyze the parameter values and incrementcorresponding counter values according to the analysis.

An exemplary counter table 200 is shown in FIG. 2A. In this example, theparameters are indicative of an internal actuator temperature (° C.).The output of a temperature sensor is continuously sensed (which caninclude discretely sampled signals at a sample interval) and the sensedtemperature values are repeatedly identified. As shown, an actuatortemperature range (° C.) 202 of −40 to 65 (° C.) has been subdividedinto the following temperatures ranges: 65-51, 50-36, 35-11, 10-(−5),(−4)-(−14), (−15)-(−25), and (−26)-(−40). In this example, the rate atwhich signals are sensed (e.g. sampled) 202 is every 1 millisecond (ms).In other examples, the sample rate may be every 1 nanosecond (ns), 1microsecond (vs), 1 second (s), 5 s, 10 s, 60 s, 1 minute, 10 minutes, 1hour, 12 hours, 24 hours, and/or any other suitable time period. Incertain embodiments, once the signal has been sensed (e.g. sample), thesignal may be analyzed to identify the corresponding actuatortemperature 202. For example, as shown in FIG. 2A, after the firstmillisecond, the sampled signal is analyzed and the identifiedtemperature 204 is identified as 34.9° C. Since 34.9° C. falls withinthe range of 35-11, 34.9 is placed in the corresponding 3^(rd) row ofthe identified temperature column 204. Turning now to FIG. 2B, afterwhich 10 ms have passed, ten actuator 10 temperatures have beenidentified. In this case, the temperatures 34.9, 35.1, 35.6, 35.8, 35.9,35.4, 34.9, and 34.8 are identified and placed in the corresponding3^(rd) row of the identified temperature column 204 and the temperatures36.1, and 36.2 are identified and placed in the corresponding 2^(nd) rowof the identified temperature column 204.

Turning now to FIG. 2C, in this example, the rate at which theidentified temperatures 204 are averaged is every 1 second. In otherexamples, the rate may be every 1 ns, 1 μs, 1 ms, 5 s, 10 s, 60 s, 1minute, 10 minutes, 1 hour, 12 hours, 24 hours, or any other suitablerate. In some cases, the identified temperatures 204 may not be averagedand the counter values 208 corresponding to each identified temperature204 may be incremented. In some cases, instead of averaging the countervalues 208 at a certain rate, the actuator may select one or more ofidentified temperatures 204 at a certain rate and the counter valuesthat correspond to the selected identified temperatures 204 may beincremented. However, in this example, after the signal has been sensedand analyzed for 1 sec, 1000 identified temperatures 204 may berecorded. The actuator may then find the average temperature 206 for the1000 identified temperatures and increment the counter value 208 thatcorresponds to the average temperature. As shown, in this case, theaverage temperature is 34.6 and the corresponding 3^(rd) row of thecounter value column 208 is incremented to 1. Rather than using anaverage, it is contemplated that the min temperature, maximumtemperature, 3 sigma temperature from the standard deviationtemperature, and/or any other approach for assigning a temperaturerepresentative of the corresponding time period.

Turning to FIG. 2D, which shows the counter table after 24 hours havepassed. In this example, 86,400 average temperatures have beencalculated. In this case, 23,119 of the average temperatures are in the50-36 range and 63,281 of the average temperatures are in the 35-11range. Accordingly, the corresponding counter value 208 in the 2^(nd)row has been incremented to 23,119 and the corresponding counter value208 in the 3^(rd) row has been incremented to 63,281. Since an averagetemperature 206 did not fall within the other actuator temperatureranges, the corresponding counter values 208 remain at 0 for thisexemplary 24 hour interval.

Turning to FIG. 2E, which shows the counter table after 6 months havepassed. In this example, 15,811,200 average temperatures have beencalculated. In this case, 1,503,436 of the average temperatures are inthe 65-51 range, 3,964,600 of the average temperatures are in the 50-36range, 5,952,800 of the average temperatures are in the 35-11 range,1,611,725 of the average temperatures are in the 10-(−5) range,1,389,320 of the average temperatures are in the (−4)-(−14) range,926,213 of the average temperatures are in the (−15)-(−25) range, and463,106 of the average temperatures are in the (−26)-(−40) range.Accordingly, the corresponding counter value 208 in the 1^(st) row hasbeen incremented to 1,503,436, the corresponding counter value 208 inthe 2^(nd) row has been incremented to 3,964,600, the correspondingcounter value 208 in the 3^(rd) row has been incremented to 5,952,800,the corresponding counter value 208 in the 4^(th) row has beenincremented to 1,611,725, the corresponding counter value 208 in the5^(th) row has been incremented to 1,389,320, the corresponding countervalue 208 in the 6^(th) row has been incremented to 926,213, and thecorresponding counter value 208 in the 7^(th) row has been incrementedto 463,106 for this exemplary six month interval. FIG. 2F is a graphicalrepresentation of the counter table of FIG. 2E.

While FIGS. 2A-2E use a counter table to help explain an illustrativeapproach for determining and maintaining various counter values, itshould be recognized that the actual algorithm implementation may bedifferent. For example, to limit the amount of memory required, all ofthe identified temperatures 204 need not be stored along with all of theaverage temperatures 206. Instead, the controller may simply maintain arunning average for each average period (1 s) by adding the incomingsensed temperatures during that period to a cumulative value, and thendividing the cumulative value by the total number of incoming sensedtemperatures that have been processed during the particular averageperiod. In this implementation, only a cumulative value and a counter ofthe total number of incoming sensed temperatures that have beenprocessed during the particular average period need be stored in memory.At the end of the particular average period, the resulting average valuemay be used to increment the appropriate counter value 208. Both thecumulative value and the counter of the total number of incoming sensedtemperatures during the particular average period may be reset for useduring the next average period.

According to various embodiments, the influence that the identifiedtemperatures 204 have on the operational status of the actuator 100 maybe determined. This may be determined by the processing module 104 ofthe actuator 100, but more preferably by a remote server or the like.For example, a remote server may receive the counter values from manyactuators that have failed. The remote server may use this data todetermine counter patterns that can help predict when an actuator islikely to fail. From this determination, a failure model (e.g., failuremodel 138, from FIG. 1) may be created. This failure model may be passedto the actuator 100 or remain on the remote server. In some cases, theactuator and/or remote server may compare the recorded counter values308 (e.g. from any of the exemplary FIGS. 2C-2E) against the failuremodel to determine a probability of failure of the actuator over time.In this regard, a user may be provided with the insight into the healthor status of the actuator 100, which may allow the user to take theproper course of action so that the building control devices of thebuilding automation system may be replaced before they are projected tofail.

FIG. 3A-3E show another exemplary counter table over time. An exemplarycounter table 300 is shown in FIG. 3A. In this example, the parametersare indicative of the operational load current (mA) of the actuator(e.g., actuator 100, from FIG. 1). Accordingly, the signals arecontinuously sensed (which can include discretely sampled signals at asample interval) and the load current values are repeatedly identified.As shown, a load current (mA) range 302 of 0 to 100 (mA) may besubdivided into the following load current ranges: 0-29, 30-39, 40-49,50-59, 60-69, 70-79, 80-89, and 90-100 (mA). In this example, the rateat which signals are sensed (e.g. sampled) is 1 millisecond (ms). Inother examples, the rate may be every 1 nanosecond (ns), 1 microsecond(vs), 1 second (s), 5 s, 10 s, 60 s, 1 minute, 10 minutes, 1 hour, 12hours, 24 hours, or any other suitable time period. In certainembodiments, once the signal has been sensed, the signal may be analyzedto identify the corresponding load current 304. For example, as shown inFIG. 3A, after the first millisecond, the signal is analyzed and theidentified load current is 57.2 mA. Since 57.2 mA falls in the range of50-59, 57.2 is placed in the corresponding 4^(th) row of the identifiedload current column 304. Turning now to FIG. 3B, after which 10 ms haspassed, ten actuator load currents 10 have been identified. In thiscase, the load currents 57.2, 58.7, and 58.9 are identified and placedin the corresponding 4^(th) row of the identified load current column304, the load currents 61.3, 63.5, 67.7, and 68.5 are identified andplaced in the corresponding 5^(th) row of the identified load currentcolumn 304, and the load currents 70.3, 70.6, and 70.2 are identifiedand placed in the corresponding 6^(th) row of the identified loadcurrent column 304.

Turning to FIG. 3C, in this example, the rate at which the identifiedload currents 304 are averaged is 1 second. In other examples, the ratemay be every 1 ns, 1 μs, 1 ms, 5 s, 10 s, 60 s, 1 minute, 10 minutes, 1hour, 12 hours, 24 hours, or any other suitable rate. In some cases, theidentified load currents 304 may not be averaged and the counter values308 corresponding to each identified load current 304 may beincremented. In some cases, instead of averaging the load currents 304at a certain rate and incrementing the counter values 308, the actuatormay select one or more of identified load currents 304 at a certain rateand the counter values that correspond to the selected identified loadcurrents 304 may be incremented. However, in this example, after thesignal has been sensed and analyzed for 1 sec, 1000 identified loadcurrents 304 may be recorded. The actuator may then find the averageload current 306 for the 1000 identified load currents and increment thecounter value 308 that corresponds to the average load current. Asshown, in this case, the average load current is 67.3 and thecorresponding 5^(th) row of the counter value column 308 is incrementedto 1.

Turning to FIG. 3D, which shows the counter table after 24 hours havepassed. As such, in this example, 86,400 average load currents arecalculated. In this case, 30,246 of the average load currents are in the50-59 range, 53,724 of the average load currents are in the 60-69 range,and 12,430 of the average load currents are in the 70-79 range.Accordingly, the corresponding counter value 308 in the 4^(th) row isincremented to 30,246, the corresponding counter value 308 in the 5^(th)row is incremented to 53,724, and the corresponding counter value 308 inthe 6^(th) row is incremented to 12,430. Since an average load currentdid not fall within the other load current ranges, the correspondingcounter values 308 remain at 0 for this exemplary 24 hour interval.

Turning to FIG. 3E, which shows the counter table after 6 months havepassed. In this example, 15,811,200 average load currents arecalculated. In this case, 384,212 of the average load currents are inthe 0-29 range, 723,893 of the average load currents are in the 30-39range, 1,224,639 of the average load currents are in the 40-49 range,3,865,312 of the average load currents are in the 50-59 range, 4,836,230of the average load currents are in the 60-69 range, 3,264,977 of theaverage load currents are in the 70-79 range, 1,083,196 of the averageload currents are in the 80-89 range, and 428,741 of the average loadcurrents are in the 90-100 range. Accordingly, the corresponding countervalue 308 in the 1^(st) row is incremented to 384,212, the correspondingcounter value 308 in the 2^(nd) row is incremented to 723,893, thecorresponding counter value 308 in the 3^(rd) row is incremented to1,224,639, the corresponding counter value 308 in the 4^(th) row isincremented to 3,865,312, the corresponding counter value 308 in the5^(th) row is incremented to 4,836,230, the corresponding counter value308 in the 6^(th) row is incremented to 3,264,977, the correspondingcounter value 308 in the 7^(th) row is incremented to 1,083,196, and thecorresponding counter value 308 in the 8^(th) row is incremented to428,741 for this exemplary six month interval. FIG. 3F is a graphicalrepresentation of the counter table of FIG. 3E.

While FIGS. 3A-3E use a counter table to help explain an illustrativeapproach for determining and maintaining various counter values, itshould be recognized that the actual algorithm implementation may bedifferent. For example, to limit the amount of memory required, all ofthe identified load currents 304 need not be stored along with all ofthe average load currents 306. Instead, the controller may simplymaintain a running average for each average period (1 s) by adding theincoming sensed load currents during that period to a cumulative value,and then dividing the cumulative value by the total number of incomingsensed load currents that have been processed during the particularaverage period. In this implementation, only a cumulative value and acounter of the total number of incoming sensed load currents that havebeen processed during the particular average period need be stored inmemory. At the end of the particular average period, the resultingaverage value may be used to increment the appropriate counter value308. Both the cumulative value and the counter of the total number ofincoming sensed load currents during the particular average period maybe reset for use during the next average period.

According to various embodiments, the influence that the identified loadcurrents 304 have on the operational status of the actuator 100 may bedetermined. This may be determined by the processing module 104 of theactuator 100, but more preferably by a remote server or the like. Forexample, a remote server may receive the counter values from manyactuators that have failed. The remote server may use this data todetermine patterns that can help predict when an actuator is likely tofail. From this determination, a failure model (e.g., failure model 138,from FIG. 1) may be created. This failure model may be passed to theactuator 100 or remain on the remote server. In some cases, the actuatorand/or remote server may compare the recorded counter values 308 (e.g.from any of the exemplary FIGS. 3C-3E) against the failure model todetermine a probability of failure of the actuator over time. In thisregard, a user may be provided with the insight into the health orstatus of the actuator 100, which may allow the user to take the propercourse of action so that the building control devices of the buildingautomation system may be replaced before they are projected to fail.

In various embodiments, the actuator may sense multiple signals andincrement counter value(s) based on multiple identified parameters. FIG.4 depicts an exemplary counter table 400 for an actuator that sensessignals for parameters indicative of both the actuator (e.g., actuator100, from FIG. 1) temperature (° C.) and the operational load current(mA) of the actuator. In this example, at a rate of one millisecond, theactuator analyzes the signals to identify the temperature of actuator todetermine its corresponding range of temperatures and identifies theload current to determine its corresponding range of load currents. Inthis example, at a rate of one second, the average temperature for theidentified temperatures is found and the average load current for theidentified load currents is found. In this example, the actuator maythen increment the counter value in the cell (e.g. particular counter)that corresponds to both the average temperature and the average loadcurrent for that period. For example, as seen in FIG. 4, cell A showsthat 1500 average temperatures of the actuator are found to be in thetemperature range of (−25° C.) to (−15° C.) with average load currentsin the range of 90-100 mA. Cell B shows that 187500 average temperaturesof the actuator are found to be in the temperature range of 36° C. to50° C. with average load currents in the range of 50-59 mA. Cell C showsthat 87500 average temperatures of the actuator are found to be in thetemperature range of (−4° C.) to 10° C. with average load currents inthe range of 50-59 mA. Each cell in the table 400 may correspond to acounter in counter block 122 of actuator 100. Similar to the examplesdiscussed in regard to FIGS. 2A-2F and 3A-3F, in some cases, theactuator 100 may compare the recorded counter values from table 400against a failure model to determine a probability of failure of theactuator over time

In some cases, the number of open/close cycles of the actuatable output(e.g., the actuatable output 120, from FIG. 1) experienced by theactuator (e.g., actuator 100, from FIG. 1), the number of positionchanges of the actuatable output experienced by the actuator, the numberof stalls of the actuatable output experienced by the actuator, and/orother parameters may be recorded by one or more counters. Suchparameters may also be indicative of the status of the surroundings orenvironment of the actuator and/or the state or operating status of theactuator 100.

In some cases, the actuatable output 120 may stall due to an obstructionin the building control device, dirt/dust buildup, a lack of lubricantand/or change in viscosity of a lubricant due to temperature changes,and/or other causes. A stall may stress the drive motor 118, a drivetrain such as gear train (not shown) and/or the actuatable output 120,and in some cases, shorten the life of the actuator. In some cases, thespeed of the actuatable output 120 at the time of the stall may provideadditional information about the potential stress introduced by a stall.As such, the number of stalls of the actuatable output experienced bythe actuator, and in some cases, the speed of the actuator at the timeof the stall may be captured in one or more counter values. In anotherexample, the number of open/close cycles of the actuatable output mayprovide a measure of the actual use of the actuator 100. An actuatorthat is opened/closed hourly will likely fail faster than a similaractuator that is actuated weekly. As a result, the higher the number ofopen/close cycles, the faster that actuator may be expected to fail.

Since the open/close cycles, the position changes, and/or the number ofstalls of the actuatable output experienced by the actuator may varyover time, in some cases, the actuator may repeatedly identify theopen/close cycles, the position changes, and the stalls of theactuatable output at a specific rate or rates. The actuator may thenanalyze the open/close cycles, the position changes, and the stalls ofthe actuatable output and increment their corresponding counter valuesaccordingly. Also, other conditions (e.g. temperature, etc.) presentduring each open/close cycle, position change, and/or stall may berecorded in a multi-parameter table similar to that shown in FIG. 4.

FIG. 5 depicts an exemplary counter table 500 for an actuator thatsenses signals for parameters indicative of both the actuator (e.g.,actuator 100, from FIG. 1) temperature (° C.) and the operational loadcurrent (mA) of the actuator. The counter table 500 is similar to thecounter table 400 of FIG. 4, with the addition of a Stall open column502, a Stall close column 504, and a Total Cycles counter 506. Incertain embodiments, if or when the actuator stalls, the actuator 100may determine whether the actuatable output is in an open position or aclosed position. The actuator may also identify the actuatortemperature. Accordingly, the actuator 100 may increment a countervariable for either the Stall open column 502 or the Stall close column504 in the row that corresponds to the temperature range the includesthe identified actuator temperature. Furthermore, in some cases, theactuator may repeatedly increment a Total Cycles counter 506 thatrecords the total open/close cycles over the lifetime of the actuator100. FIG. 5B is a graphical representation of the counter table of FIG.5A.

According to various embodiments, the influence that the identified loadcurrents, the identified temperatures, the open/close cycles, and/or thestalls of the actuatable output have on the operational status of theactuator may be determined. From this determination, a failure model(e.g., failure model 138, from FIG. 1) may be created. In some cases,the actuator may measure the recorded counter values from FIG. 5Aagainst the failure model to determine a probability of failure of theactuator over time. This failure model may be passed to the actuator 100or may be on a remote server. In some cases, the actuator and/or remoteserver may compare the recorded counter values from FIG. 5A against thefailure model to determine a probability of failure of the actuator 100over time. In this regard, a user may be provided with the insight intothe health or status of the actuator 100, which may allow the user totake the proper course of action so that the building control devices ofthe building automation system may be replaced before they are projectedto fail.

FIG. 6 is a schematic block diagram of an illustrative buildingautomation system 600. In certain embodiments, the building automationsystem 600 may include a controller 602 and building control devices 626operatively coupled to the controller 602. As shown, the buildingcontrol devices 626 may include, but are not limited to, a Heating,Ventilation, and/or Air Conditioning (HVAC) devices 628, 632, and 634.In other embodiments, the building control devices 626 may include moredevices, such as security system devices, fire system devices, accesscontrol system device, and lighting system devices, for example. In someembodiments, the HVAC devices 628, 632, and 636 may include one or moreAir Handing Units (AHU), Variable-Air-Volume (VAV) units, dampers,valves, fans, heating units, cooling units, sensors, thermostats,humidifiers, dehumidifiers etc., which allow for the monitoring and/orcontrol of temperature and/or other environmental conditions in abuilding.

In the example shown, the controller 602 can perform variouscommunication and data transfer functions and can execute one or moreapplication functions. The components of controller 602 may include, butare not limited to, a processing module 604, memory 608, and a bus 622that couples various system components including the memory 608 to theprocessing module 604. The processing module 604 may executeinstructions stored in the memory 608. Moreover, the processing module604 and the memory 608 may be configured similar to the processingmodule 104 and the memory 112 of the actuator 100 described with respectto FIG. 1. According to various embodiments, the processing module 604and the memory 608 may have additional functionality and storagecapacity as desired to facilitate proper management of the buildingcontrol devices 626 and communication with external device (e.g., HVACdevices 628, 632, 636 and a server). The controller 602 may be part of aremote server.

The memory 608 can include computer system readable media in the form ofvolatile memory, such as random access memory (RAM) 610 and/or cachememory 612. Controller 602 may further include otherremovable/non-removable, volatile/non-volatile computer system storagemedia. By way of example only, storage system 614 can be provided forreading from and writing to a non-removable, non-volatile magnetic media(not shown and typically called a “hard drive”).

Similar to program/utility 134 of FIG. 1, program/utility 616 may bestored in the memory 608 and may include a set of application programmodules (e.g. software), such as the parameter counter module 136. Insome cases, the program/utility 616 may include additional programmodules as well as an operating system, one or more other applicationprogram modules, and program data. According to various embodiments, theapplication program modules (e.g., the parameter counter module 136) mayinclude the actuator failure model 138, for example. In certainembodiments, the parameter counter module 136, including the actuatorfailure model 138, may be assembler instructions,instruction-set-architecture (ISA) instructions, machine instructions,machine dependent instructions, microcode, firmware instructions,state-setting data, or either source code or object code written in anycombination of one or more programming languages, including an objectoriented programming language such as Smalltalk, C++ or the like, andconventional procedural programming languages, such as the “C”programming language or similar programming languages.

The parameter counter module 136 may execute on the controller 602. Insome cases, the parameter counter module 136 may execute on a remotedevice (e.g., actuators 630, 634, or 638 or a server). In some cases,part of the parameter counter module 136 may be executed on thecontroller 602 and part of the parameter counter module 136 may beexecuted on a remote device. In the latter scenario, the controller 602may be connected to the remote device, such as the building controldevices 626, through any type of network, including a local area network(LAN) or a wide area network (WAN), or the connection may be made to anexternal computer (for example, through the Internet using an InternetService Provider). In certain instances, a network adapter 606 isinclude in the controller 602 to support such communication.

In various embodiments, the controller 602 may communicate with one ormore devices such as the building control devices 626 and thus, theactuators 630, 634, and 638 via Input/Output (I/O) interface(s) 624. Insome cases, the building control device 626 building may be managed bythe controller 602. In certain embodiments, the controller 602 may usethe processing module 604 to send control instructions to the buildingcontrol device 626. For instance, the processing module 604 may beoperatively coupled to I/O interface(s) 624 via the bus 622, and may usethe I/O interface 624 to communicate with the actuators 630, 634, and638 of the building control devices 626.

In some cases, the I/O interface 624 may be connected to the buildingcontrol devices 626 through a wired or wireless network, and in somecases may communicate with building control devices 626 using one ormore communication protocol. For example, in certain embodiments, theI/O interface 624 may communicate with the HVAC devices 628, 632, and636 through serial and/or parallel communication using buildingautomation protocols over a BACnet. This is just one example of buildingcontrol network protocols that may be used to facilitate communicationbetween the controller 602 and the building control devices 626. Otherbuilding control network protocols that are contemplated include, butare not limited to, 1-Wire, C-Bus, CC-Link Industrial Networks, DSI,Dynet, KNX, LonTalk, oBIX, VSCP, xAP, X10, Z-Wave, ZigBee, INSTEON,TCIP, and/or Ethernet.

In certain embodiments, the I/O interface 624 may be configured tocommunicate with the actuators 630, 632, and 634 to send and/or receivediagnostic information (e.g., counter value(s), a failure model 138,and/or a probability of failure of the actuator) to and from theactuators 630, 632, and 634 and/or other information regarding theactuators 630, 632, and 634. For example, in some cases, the actuators630, 632, and 634 may receive information, such as, the failure model138 in the form of signals, data, commands or instructions and/ormessages from the controller 602 through the I/O interface 624. Theactuators 630, 632, and 634 may send current counter value(s), anupdated failure model 138, and/or a probability of failure to thecontroller 602 through the I/O interface 624. The controller 602 may usethe processing module 604 to organize and/or combine the data from aplurality of actuators (e.g., actuators 630, 634, and 638) to producemore accurate failure models that can be used to diagnose the overalloperating status for the actuators 630, 634, and 638 and/or otheractuators. In some cases, the controller 602 may be operated by themanufacturer of the actuators, and may receive data, and the controller602 may receive the counter values from many actuators in the field asthey fail. These actuators may be installed throughout the country orworld at various customer sites. The controller 602 may use this data todetermine counter patterns that can help predict when an actuator islikely to fail. From this determination, a failure model (e.g., failuremodel 138, from FIG. 1) may be created and/or updated by the controller602. In some cases, an updated failure model may be downloaded to theactuators, such as to actuators 630, 634 and 638.

FIG. 7 is a schematic block diagram of another illustrative buildingcontrol system 700. In certain embodiments, the building control system700 may include a server 702 and the building automation system 600. Asshown, the building automation system 600 includes the controller 602,from FIG. 6, and several additional controllers 732A-732E. Thecontrollers 602 and 732A-732E are exemplary devices that each provide abuilding control function. Each of the controllers 602 and 732A-732E mayinclude suitable logic, circuitry and/or code for storing one or moreparameters associated with the operation of corresponding buildingcontrol devices (e.g., the building control devices 626, from FIG. 6).In various embodiments, the controllers 732A-732E may control devices ofan HVAC system, a security system, a fire system, an access controlsystem, and a lighting system, for example. In some cases, the devicesof a security system may include, sensors, alarm devices, audio/visualdevices, lights, contact sensors for monitoring the state of doors andwindows, security card pass systems, electronic locks, etc. In somecases, the devices of a fire system may include smoke/heat sensors, asprinkler system, warning lights, etc. In some cases, the devices of anaccess control system may include doors, door locks, windows, windowlocks, turnstiles, parking gates, elevators, or other physical barrier,where granting access can be electronically controlled. In some cases,the devices of a lighting system may include emergency lights, outlets,lighting, drapes, and general load switching, some of which are subjectto “dimming” control which varies the amount of power delivered to thevarious building control devices. These are just a few examples ofbuilding control devices. In some cases, the building control devicesmay also include low voltage devices that may include, but are notlimited to, garage door openers, lawn sprinklers, exterior lights, andpool/spa heaters (controlled via a relay or the like).

In some cases, the building automation system 600 may be managed orcontrolled using the server 702 that is operatively connected to thecontrollers 602 and 732A-732. In some cases, the server 702 may beoperatively connected to the building automation system 600 through awired or wireless network 730. In some examples, the network 730 may bea local area network (LAN), a general wide area network (WAN), and/or apublic network (e.g., the Internet). Furthermore, in some cases, thenetwork 730 may comprise copper transmission cables, opticaltransmission fibers, wireless transmission, routers, firewalls,switches, gateway computers and/or edge servers. In certain instances, anetwork adapter is included in the server 702 (e.g., the network adapter706) and/or a network adapter (not shown) is included with eachcontroller (e.g., the network adapter 606) to support communication. Insome cases, the building automation system 600 includes the server 702.

As shown in FIG. 7, the server 702 may be in the form of ageneral-purpose computing system, but this is not required. In somecases, the server 702 may be a special purpose computing system. Thecomponents of the server 702 may include, but are not limited to, one ormore processors or processing modules 704, memory 708, and a bus 722that couples various system components including system memory 708 tothe processing module 704. The processing module 704 and the memory 708may be configured similar to the processing module 604 and the memory608 of the controller 602 described with respect to FIG. 6. Forinstance, program/utility 716 may be stored in the memory 708 and mayinclude a set of application program modules (e.g. software), such asthe parameter counter module 136. In some cases, the program/utility 716may include additional program modules as well as an operating system,one or more other application program modules, and program data.According to various embodiments, the application program modules (e.g.,the parameter counter module 136) may include an actuator failure model138, for example. In certain embodiments, the parameter counter module136, including the actuator failure model 138, may be assemblerinstructions, instruction-set-architecture (ISA) instructions, machineinstructions, machine dependent instructions, microcode, firmwareinstructions, state-setting data, or either source code or object codewritten in any combination of one or more programming languages,including an object oriented programming language such as Smalltalk, C++or the like, and conventional procedural programming languages, such asthe “C” programming language or similar programming languages.

The parameter counter module 136 may execute on the server 702. In somecases, the parameter counter module 136 may execute on a remote device(e.g., actuators 630, 634, or 638, from FIG. 6, or controllers 602 and732A-732E of FIG. 7). In some cases, part of the parameter countermodule 136 may be executed on the server 702 and part of the parametercounter module 136 may be executed on a remote device. In the latterscenario, the server 702 may be connected to the remote device, such asthe controllers 602 and 732A-732E through any type of network (e.g.,network 730) and communicate information regarding the parameter countermodule 136 over the network. For example, in some cases, the server 702may communicate with one or more of the controllers 602 and 732A-732Eand thus, the actuators controlled by the controllers 602 and 732A-732Evia the network 730. In certain embodiments, the server 702 may use theprocessing module 704 to send control instructions to the buildingautomation system 600. For instance, the processing module 704 may beoperatively coupled to the network adapter 706 via the bus 722, and mayuse the network adapter 706 to communicate over the network 730 to theactuators (e.g., 630, 634, and 638, from FIG. 6) of the buildingautomation system 600.

In certain embodiments, the network adapter 706 may be configured tocommunicate over the network 730 with the controllers 602 and 732A-732Eand/or the actuators to receive and provide diagnostic information(e.g., counter value(s), the failure model 138, a probability of failureof the actuators) to and from the controllers 602 and 732A-732E and/oractuators. For example, in some cases, the actuators may receiveinformation, such as, the failure model 138 in the form of signals,data, commands or instructions and/or messages from the server 702. Theactuators may send current counter value(s), an updated failure model138, and/or a probability of failure to the server 702. The server 702may use the processing module 604 to organize and combine the data fromall of the actuators in the building automation system 600 (includingdata from all the controllers 602 and 732A-732E of the buildingautomation system 600) to produce more accurate failure models that canbe used to diagnose the overall operating status for the actuators 630,634, and 638 and/or other actuators.

In various embodiments, the server 702 may communicate the probabilityof failure of the actuators of the building automation system 600 withone or more external devices 728 and/or a display 726. The one or moreexternal devices 728 and the display 726 may enable a user to interactwith the server 702, and/or may enable the server 702 to communicatewith one or more other computing devices. In some cases, the server 702may output a maintenance schedule that indicated an estimated date offailure of each of the actuators. Maintenance personnel may then replacethe actuators just before their corresponding projected date of failure.This communication can occur via Input/Output (I/O) interface(s) 724.

FIG. 8 shows an example method 800 for estimating a probability offailure of an actuator. Method 800 begins at step 802, where theactuator senses a first sensed parameter in or around the actuator thathas a first sensed parameter value that can change with time. In someexamples, the first sensed parameter values may be indicative of thestatus of the surroundings or environment of the actuator and/or theoperating status of the actuator. For example, the first sensedparameter values may include values regarding the operational loadcurrent of the actuator, the internal temperature of the actuator, thetemperature surrounding the actuator, the humidity levels surroundingthe actuator, the atmospheric pressure surrounding the actuator, thedifferential pressure within the actuator, the speed and direction ofthe air surrounding the actuator, the quality of the air surrounding theactuator, etc. Since the actuators surroundings and the actuatorsoperating status may change over time, the first sensed parameter valuesmay also change over time. At step 804, the actuator may repeatedlyidentify a first identified value representative of the first sensedparameter value. The first identified value may be a sensed value, a maxvalue over a predefined interval, a minimum value over a predefinedinterval, an average of the sensed values over a predefined interval, orany other value representative of the first sensed parameter value. Atstep 806, for each first identified value, the actuator may increment afirst counter value when the first identified value falls within a firstrange of values, and increment a second counter value when the firstidentified value falls within a second range of values, and the firstrange of values may be different from the second range of values. Atstep 808, the actuator may calculate the probability of failure of theactuator based at least in part on the first counter value and/or thesecond counter value. In some cases, the influence the first sensedparameter has over the operating condition of the actuator may bedetermined. From this determination, a failure model may be created. Insome cases, the actuator may measure the first counter value and/orsecond counter value against the failure model to determine theprobability of failure of the actuator. The method 800 may then returnto step 802.

Method examples described herein can be machine or computer-implementedat least in part. Some examples can include a computer-readable mediumor machine-readable medium encoded with instructions operable toconfigure an electronic device to perform methods as described in theabove examples. An implementation of such methods can include code, suchas microcode, assembly language code, a higher-level language code, orthe like. Such code can include computer readable instructions forperforming various methods. The code may form portions of computerprogram products. Further, in an example, the code can be tangiblystored on one or more volatile, non-transitory, or non-volatile tangiblecomputer-readable media, such as during execution or at other times.Examples of these tangible computer-readable media can include, but arenot limited to, hard disks, removable magnetic or optical disks,magnetic cassettes, memory cards or sticks, random access memories(RAMs), read only memories (ROMs), and the like.

The above description is intended to be illustrative, and notrestrictive. For example, the above-described examples (or one or moreaspects thereof) may be used in combination with each other. Also, inthe above description, various features may be grouped together tostreamline the disclosure. This should not be interpreted as intendingthat an unclaimed disclosed feature is essential to any claim. Rather,inventive subject matter may lie in less than all features of aparticular disclosed embodiment. Thus, the following claims are herebyincorporated into the Description as examples or embodiments, with eachclaim standing on its own as a separate embodiment, and it iscontemplated that such embodiments can be combined with each other invarious combinations or permutations.

What is claimed is:
 1. A method for determining a health status of anactuator, the method comprising: receiving a first counter value and asecond counter value for each of a plurality of actuators, wherein thefirst counter value represents a relative amount of time an operatingcondition of the respective actuator fell within a first range and thesecond counter value represents a relative amount of time the operatingcondition of the respective actuator fell within a second range;determining a failure model based at least in part on the first countervalues and the second counter values received from the plurality ofactuators; and determining a health status of each of the plurality ofactuators based at least in part on the failure model.
 2. The method ofclaim 1, further comprising: repeatedly receiving updated first countervalues and second counter values for each of the plurality of actuators;repeatedly updating the failure model based at least in part on theupdated first counter values and second counter values; and repeatedlyupdating the health status of each of the plurality of actuators basedat least in part on the updated failure model.
 3. The method of claim 1,wherein the first counter value and the second counter value for arespective actuator are received when the respective actuator fails. 4.The method of claim 3, wherein determining the failure model comprisesidentifying one or more patterns in the first counter values and thesecond counter values from the plurality of actuators that arepredictive of the health status.
 5. The method of claim 1, wherein theplurality of actuators are installed in a plurality of differentfacilities.
 6. The method of claim 1, wherein the receiving, determininga failure model and determining a health status are performed by aserver.
 7. The method of claim 1, wherein the server is operated by amanufacturer of the plurality of actuators.
 8. The method of claim 1,wherein the plurality of actuators are of a common actuator type.
 9. Themethod of claim 1, wherein the plurality of actuators comprise one of avalve, a damper, and a door lock.
 10. The method of claim 1, furthercomprising receiving a count of a total number of operating cycles foreach of the plurality of actuators, and determining the failure modelbased at least in part on the count of the total number of operatingcycles received from the plurality of actuators.
 11. The method of claim1, further comprising receiving a count of a total number of stalls foreach of the plurality of actuators, and determining the failure modelbased at least in part on the count of the total number of stallsreceived from the plurality of actuators.
 12. The method of claim 1,wherein the operating condition comprises one of: a sensed temperaturein or around the respective actuator, a motor current for a motor of therespective actuator, a number of stalls of the respective actuator, anda motor speed at each of the number of stalls of the respectiveactuator.
 13. The method of claim 1, wherein the health status includesa probability of failure over time.
 14. The method of claim 1, whereinthe health status includes an estimated date of failure for each of theplurality of actuators.
 15. A method for determining a health status ofan actuator, the method comprising: receiving a first counter value, asecond counter value, a third counter value and a fourth counter valuefor each of a plurality of actuators, wherein: the first counter valuerepresents a relative amount of time that a first operating condition ofthe respective actuator fell within a first range and a second operatingcondition of the respective actuator fell within a third range; thesecond counter value represents a relative amount of time that the firstoperating condition of the respective actuator fell within the firstrange and the second operating condition of the respective actuator fellwithin a fourth range; the third counter value represents a relativeamount of time that the first operating condition of the respectiveactuator fell within a second range and the second operating conditionof the respective actuator fell within the third range; the fourthcounter value represents a relative amount of time that the firstoperating condition of the respective actuator fell within the secondrange and the second operating condition of the respective actuator fellwithin the fourth range; determining a failure model based at least inpart on the first counter values, the second counter values, the thirdcounter values and the fourth counter values received from the pluralityof actuators; and determining a health status of each of the pluralityof actuators based at least in part on the failure model.
 16. The methodof claim 15, further comprising: repeatedly receiving updated firstcounter values, second counter values, third counter values and fourthcounter values for each of the plurality of actuators; repeatedlyupdating the failure model based at least in part on the updated firstcounter values, second counter values, third counter values and fourthcounter values; and repeatedly updating the health status of each of theplurality of actuators based at least in part on the updated failuremodel.
 17. The method of claim 15, wherein the first counter value, thesecond counter value, the third counter value and the fourth countervalue for a respective actuator are received when the respectiveactuator fails.
 18. The method of claim 17, wherein determining thefailure model comprises identifying one or more patterns in the firstcounter value, the second counter value, the third counter value and thefourth counter value from the plurality of actuators that are predictiveof the health status.
 19. The method of claim 15, wherein the pluralityof actuators are installed in a plurality of different facilities, andthe receiving, determining a failure model and determining a healthstatus are performed by a server.
 20. A server comprising: a receiverfor receiving a first counter value and a second counter value for eachof a plurality of actuators, wherein the first counter value representsa relative amount of time an operating condition of the respectiveactuator fell within a first range and the second counter valuerepresents a relative amount of time the operating condition of therespective actuator fell within a second range; a processor operativelycoupled to the receiver, the processor configured to: determine afailure model based at least in part on the first counter values and thesecond counter values received from the plurality of actuators; anddetermine a health status of each of the plurality of actuators based atleast in part on the failure model.